JP2007054466A - Method for manufacturing pored pillow - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a pored pillow, capable of manufacturing a pored pillow with good work efficiency and at low cost. <P>SOLUTION: This method for manufacturing a pored pillow comprises a compression process to compress a foam member 11 disposed between two pressure members 21 and 31 provided with punching holes 22 and 23 at the same positions to be compressed with the two pressure members, a punching and pushing process to insert punching blades 51 from the punching hole 32 in one pressure member 31 to the punching hole 22 in the other pressure member 21 to punch the foam member 11 between the two pressure members, and push punched parts 13 from the punching hole 22 in the other pressure member 21 outward of the foam member to open a through hole 12 in the foam member 11, and a compression release process to release compression in the foam member 11 by expanding the interval between the two pressure members 21 and 31. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a perforated pillow having through holes.

  Some pillows made of foam are made of perforated foam with through-holes to prevent stuffiness during use. In recent years, a foam having a low-rebound foam has been proposed.

  Conventionally, when manufacturing a perforated pillow, the foam is placed on a support base, and the Thomson blade is lowered from above the foam and pressed into the foam to be punched into a Thomson blade shape. A through-hole is formed in the foam by drawing.

  However, punching with a Thomson blade leaves a punched portion in the foam after the Thomson blade is pulled out of the foam, and the punched portion must be manually removed from the foam after that, which makes the operation complicated. Cost.

  There is also a method of forming through holes one by one in the foam by a drill or the like, but there is a problem that it takes time and labor to form a plurality of through holes.

  In addition, low-rebound foam has not only low rebound properties but also slow recovery that requires time to recover after pressure deformation, so the foam adheres to the blade during drilling and cutting. There is a problem that is difficult to process.

JP 2004-243044 A JP 2002-233441 A

  This invention is made | formed in view of the said point, Comprising: It aims at manufacturing a perforated pillow at work efficiency and cheaply.

  In the invention of claim 1, in the manufacture of a perforated pillow having a through-hole formed in a foam, compression is performed by placing the foam between two pressing bodies formed with punching holes and compressing the two pressing bodies. And pressing the punching blade from the punching hole of one pressing body toward the punching hole of the other pressing body, punching the foam between the two pressing bodies with the punching blade, and A punching and extruding process in which a punching blade is used to push out from the punching hole of the other pressing body to the outside of the foam to open a through hole in the foam, and the foam is compressed by expanding the space between the two pressing bodies. A perforated pillow is formed by a compression release process for releasing the body.

  In the invention of claim 2, in the production of a perforated pillow having a through-hole formed in a foam, a polyol (A-1) having a functional group number of 1.5 to 4.5 and a hydroxyl value of 150 to 300 mgKOH / g, and the number of functional groups A polyol (A) having an average hydroxyl value of 90 to 250 mgKOH / g and a polyol (A-2) having a weight ratio of 1.5 to 4.5 and a hydroxyl value of 30 to 100 mgKOH / g in a weight ratio of 50:50 to 80:20; After the polyisocyanate (B) is reacted with an isocyanate index of 60 to 90 in the presence of a foaming agent and a catalyst to form a foam, the foam is disposed between two pressing bodies in which punching holes are formed. A compression step of compressing with the two pressing bodies, and a punching blade is press-fitted from the punching hole of one pressing body toward the punching hole of the other pressing body, and the foam between the two pressing bodies is in front A punching and extruding step of punching with a punching blade, and extruding a punched portion from the punching hole of the other pressing body to the outside of the foam with the punching blade to open a through hole in the foam, and the two pressings A perforated pillow is formed by a compression release step of expanding the space between the bodies to release the compression of the foam.

  The invention of claim 3 is characterized in that, in claim 1 or 2, the foam is a low resilience foam having a resilience elastic modulus of 30% or less.

  According to a fourth aspect of the present invention, in any one of the first to third aspects, the foam is a molded product.

  A fifth aspect of the present invention is characterized in that, in any one of the first to fourth aspects, the compression ratio of the foam by the two pressing bodies is 5 to 40%.

  According to invention of Claim 1 and 2, while punching the foam between two press bodies with the said punching blade, the punched part is extruded with the said punching blade to the outward of the said foam from said other punching hole. Since the through-hole is formed in the foam, it is not necessary to remove the punched piece in a subsequent process, which is required in the case of punching with a Thomson blade, and the perforated pillow can be manufactured efficiently and inexpensively. In addition, the working efficiency can be significantly improved as compared to forming the through holes one by one in the foam by a drill or the like. Moreover, since the foam is placed between the two pressing bodies and punched while being compressed with the two pressing bodies, the foam at the time of punching is compressed and thinned, and the hardness is increased. It is possible to correctly form the through-hole by suppressing irregular deformation of the foam that occurs when punching without punching, and to perform punching efficiently by reducing the amount of advancement and retreat of the punching blade.

  According to the invention of claim 3, even when the foam is a low-rebound foam having a rebound resilience of 30% or less, it is not necessary to remove the punched piece, and the perforated pillow can be manufactured efficiently.

According to the invention of claim 4, since the foam is made of a molded product, it is not necessary to make a pillow shape by cutting after foaming by setting the molded product to a pillow shape, thereby improving work efficiency. Thus, a perforated pillow can be manufactured at low cost.

  According to the invention of claim 5, by setting the compression ratio of the foam by the two pressing bodies to 5 to 40%, the thickness of the foam is reduced and the hardness is increased at the time of punching with the punching blade. Irregular deformation of the body is suppressed, and the through hole can be formed correctly.

  Embodiments of the present invention will be described below. 1 is a schematic cross-sectional view showing a state in which a foam is disposed on a pressing body in one embodiment of the present invention, FIG. 2 is a schematic cross-sectional view showing a compressed state of the foam in the same embodiment, and FIG. FIG. 4 is a schematic cross-sectional view showing a state in which the punching blade is pulled out from the foam in the same embodiment, FIG. 5 is a schematic cross-sectional view showing a compression release state in the same embodiment, and FIG. It is a perspective view of the perforated pillow obtained by the manufacturing method of an embodiment.

  In the method for manufacturing a perforated pillow in the present invention, a perforated pillow is manufactured by performing a compression step, a punching extrusion step, and a compression release step on the foam.

  As the foam used in the present invention, a polyurethane foam having a rebound resilience of 30% or less (based on JIS K 6400) obtained by foam-molding polyol (A) and polyisocyanate (B) in the presence of a foaming agent and a catalyst. A polyurethane foam having a rebound resilience of 0 to 20% or less (based on JIS K 6400) is preferable. Furthermore, a polyurethane foam having a hardness (based on JIS K 6400) of 80 N or less, particularly a polyurethane foam having a hardness of 10 to 70 N, is more suitable for the method for producing a perforated pillow of the present invention. .

  The polyol (A) is preferably a polyol (A-1) having a functional group number of 1.5 to 4.5 and a hydroxyl value of 150 to 300 mgKOH / g, a functional group number of 1.5 to 4.5, and a hydroxyl value of 30 to 30. Those having an average hydroxyl value of 90 to 250 mgKOH / g in which 100 mgKOH / g of polyol (A-2) is made into a weight ratio of 50:50 to 80:20 are preferred. As the polyols (A-1) and (A-2), those known for polyurethane mold foams can be used. For example, as an ether polyol, a polyhydric alcohol such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, sucrose, or the polyhydric alcohol thereof Examples include polyether polyols obtained by adding alkylene oxides such as ethylene oxide and propylene oxide, and polymer polyols.

  In the polyol (A-1), when the number of functional groups is less than 1.5, a three-dimensional network structure is not generated and a foam is not obtained. On the other hand, when the number of functional groups exceeds 4.5, the viscosity of the polyol becomes high, the moldability and workability are inferior, and a flexible foam cannot be obtained. Moreover, if the hydroxyl value is less than 150 mgKOH / g, the resilience modulus of the foam is increased. On the other hand, when it exceeds 300 mgKOH / g, the temperature dependency of the foam increases.

  When the polyol (A-2) has a functional group number of less than 1.5, a three-dimensional network structure is not generated, and a resin foam cannot be obtained. On the other hand, when the number of functional groups exceeds 4.5, the viscosity of the polyol becomes high, the moldability and workability are inferior, and a flexible foam cannot be obtained. Moreover, when the hydroxyl value is less than 30 mgKOH / g, the reactivity is inferior and a good foam cannot be obtained. On the other hand, when it exceeds 100 mgKOH / g, the foam formed using the polyol (A) composed of the polyol (A-1) and the polyol (A-2) becomes highly temperature dependent.

  In order to develop low resilience in the foam, it is necessary to blend at least two types of polyols having different molecular weights. By expanding the molecular weight distribution of the polyol mixture, a foam having a plurality of glass transition points is obtained, and a foam having a high viscosity and high impact absorption with respect to a temperature change is obtained. Moreover, the foam which consists of this polyol mixture becomes a slow recovery thing which shows the recovery | restoration delay recovery slow after a press. The time required for delay recovery is usually 5 seconds or more.

  Therefore, when the weight ratio of the polyol (A-1): polyol (A-2) is out of the range of 50:50 to 80:20, the molecular weight distribution of the polyol mixture becomes narrow, and the foam having low resilience. Cannot be obtained. In addition, the polyol (A) composed of the polyol (A-1) and the polyol (A-2) has a low reaction activity and an adequately foamed foam cannot be obtained when the average hydroxyl value is less than 90 mgKOH / g. On the other hand, when the average hydroxyl value exceeds 250 mgKOH / g, the crosslinking density is high, and a foam having desired physical properties cannot be obtained.

  As the polyisocyanate (B) used in the present invention, those known for polyurethane mold foams can be used. That is, aliphatic or aromatic polyisocyanates having two or more isocyanate groups, mixtures thereof, modified polyisocyanates obtained by modifying them, and the like can be used. Examples of the aliphatic polyisocyanate include hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate. Examples of the aromatic polyisocyanate include toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, and xylylene. Range isocyanate, polymeric polyisocyanate (crude MDI), etc. can be mentioned. Other prepolymers can also be used. In the present invention, the amount of polyisocyanate (B) is such that the value of isocyanate index [isocyanate group / active hydrogen group × 100] is 60 to 90. If the isocyanate index is less than 60, a large number of unreacted hydroxyl groups will be present, resulting in a sticky foam. On the other hand, when it exceeds 90, there is no 'sloppy' feel peculiar to the low resilience foam, and desired physical properties such as a slow recovery property cannot be obtained.

  As the foaming agent used in the present invention, those known for polyurethane mold foams can be used. For example, water or hydrocarbons such as pentane can be used alone or in combination. In the case of water, carbon dioxide gas is generated during the reaction between the polyol and the polyisocyanate, and foaming is performed by the carbon dioxide gas. The amount of the foaming agent is appropriately determined. In the case of water, about 0.5 to 4 parts by weight is preferable with respect to 100 parts by weight of the polyol.

  As the catalyst used in the present invention, those known for polyurethane mold foams can be used. For example, an amine catalyst such as triethylamine or tetramethylguanidine, a tin catalyst such as stannous octoate, or a metal catalyst such as phenylmercurypropionate or lead octenoate (also referred to as an organometallic catalyst) is used. Can do. The general amount of the catalyst is about 0.01 to 6 parts by weight with respect to 100 parts by weight of the polyol.

  Moreover, it is preferable to add a foam stabilizer appropriately. As the foam stabilizer, those known for polyurethane mold foams can be used. For example, a silicone type foam stabilizer, a fluorine-containing compound type foam stabilizer, and a well-known surfactant can be mentioned. A common amount of foam stabilizer is 1 to 6 parts by weight per 100 parts by weight of polyol. Furthermore, in the present invention, an appropriate amount of an auxiliary agent such as a flame retardant, a colorant, or a plasticizer may be added.

  The foam is formed by known molding. That is, a polyol in which a mold (molding die) having a pillow-shaped molding cavity is used, and the polyol (A), a foaming agent, a catalyst, and an auxiliary agent such as a foam stabilizer added as necessary are mixed at a predetermined ratio. The component and the polyisocyanate (B) are mixed at a predetermined ratio by a known foam molding machine and filled in the cavity, and the polyol (A) and the polyisocyanate (B) are reacted in the cavity, and the cavity It is carried out by making it into a pillow-shaped foam by foaming into a shape and then removing from the mold.

  In the compression process performed on the foam thus formed, as shown in FIGS. 1 and 2, first, the foam 11 is divided into two punch holes 22 and 32 formed at the same position. It arrange | positions between the press bodies 21 and 31, and it compresses with the two press bodies 21 and 31. FIG. In the example of the figure, the foam 11 is placed on one pressing body 21 placed substantially horizontally on a support leg 41, and the other pressing body 31 positioned above the foam 11 is The foam 11 is pressed and compressed by being lowered by a pressing device (not shown). The support legs 41 are arranged at the four corners of the one pressing body 21 and form punched partial extrusion spaces 45 below the pressing body 21. In addition, the pressing bodies 21 and 31 have a plate shape in the illustrated example, and have a size capable of pressing at least a range in which the foam 11 is to be punched. In addition, the said press bodies 21 and 31 are good also as what was match | combined with the surface shape of the press part in the said foam 11. FIG. For example, when the surface of the pressing portion of the foam 11 has a concave shape, the shape of the pressing bodies 21 and 31 may be a convex shape that matches the concave shape of the foam.

  The size, the number, and the position of the punching holes 22, 32 in the pressing bodies 21, 31 are the size, the number, and the position according to the target through-hole of the perforated pillow. In particular, if the punching holes 22 and 32 are too large, when the foam 11 is pressed by the pressing bodies 21 and 31 and compressed, the foam 11 greatly expands outward at the punching holes 22 and 32. The degree of compression is low, which may adversely affect punching with a punching blade performed in a later process. If it is too small, it becomes difficult to insert the punching blade into the punching holes 22 and 32. 3-10 mm, preferably about 4-7 mm is preferable. The shape of the punching holes 22 and 32 is not limited to a circle, and may be an ellipse or a polygon such as a quadrangle or a pentagon.

  The compression of the foam 11 by the pressing bodies 21 and 31 is preferably set to a compression rate of [thickness of the compressed state of the foam 11 ÷ thickness before compression of the foam 11 × 100] of 5 to 40%. When the compression ratio is less than 5%, a large force is required to press the foam 11 by the pressing bodies 11 and 21, and the foam 11 may be difficult to restore after compression. On the other hand, when the compression ratio exceeds 40%, the foam 11 becomes insufficiently compressed, and it becomes difficult to obtain the effect of compression.

  In the punching and extruding step, as shown in FIGS. 2 and 3, the punching blade 51 is moved to one of the two pressing bodies 21 and 31 in a state where the foam 11 is compressed by the two pressing bodies 21 and 31. The pressing body 31 is pressed from the punching hole 32 toward the punching hole 22 of the other pressing body 21. Then, the foam 11 between the two pressing bodies 21 and 31 is punched by the punching blade 51 and the punched portion 13 is moved outward from the punching hole 22 of the other pressing body 21 to the foam 11. The through-hole 12 is opened in the foam 11 by extruding with a punching blade 51. In the illustrated example, the punching blade 51 is provided on the lower surface of the lifting plate 55 so as to be positioned on the upper extension line of the punching holes 22, 32 of the pressing bodies 21, 31. It is inserted into the punching hole 32 of the upper pressing body 31 by being lowered by not shown. The punching blade 51 has a diameter that can be inserted into the punching holes 22 and 32 of the pressing bodies 21 and 31, and has a length that can penetrate the foam 11 that is in a compressed state by the pressing bodies 21 and 31. . After the punching, as shown in FIG. 4, the lifting plate 55 is raised and the punching blade 51 is extracted from the foam 11. The tip 52 of the punching blade 51 may be sharpened as a blade, or may not be sharpened. Even if it is not sharpened, it can be punched by pressing the foam by pressing at the time of punching.

  In the compression release process, as shown in FIG. 5, the space between the two pressing bodies 21 and 31 is expanded to release the compression of the foam 11 to obtain the perforated pillow 10 shown in FIG.

  Polyurethane raw materials for low resilience foams having the following raw materials shown in Table 1 (numbers of each raw material are parts by weight) were filled in a mold, and the foams for perforated pillows of Examples 1 to 4 were molded. . The molding cavity of the mold has a pillow shape of 80 × 350 × 500 mm.

(Raw materials used)
Polyol (A-1): polyether polyol, average functional group number: 3, hydroxyl value: 250 mg KOH / g, trade name “G-250”, manufactured by Takeda Pharmaceutical Co., Ltd. • Polyol (A-2); polyether polyol, Average number of functional groups: 3, hydroxyl value: 36 mg KOH / g, trade name “MF78”, manufactured by Takeda Pharmaceutical Co., Ltd. • Polyisocyanate; TDI / MDI mixture, NCO%: 44%, trade name “C-1021”, Nippon Polyurethane Co., Ltd. Company made ・ Catalyst; Triethylenediamine, trade name “LV33”, manufactured by Chukyo Yushi Co., Ltd. ・ Foaming agent: Water (ion exchange water)
・ Foam stabilizer: Silicone foam stabilizer, trade name “SF2969”, manufactured by Toray Dow Corning Silicone Co., Ltd.

The foam for a perforated pillow removed from the mold was measured for density (kg / m ³ ), rebound resilience (%), and hardness (N) according to JIS K 6400. Moreover, with respect to the foam for a perforated pillow, similarly to FIGS. 1 to 5, a compression process, a punching extrusion process, and a compression releasing process are performed using two pressing bodies formed with punching holes and a punching blade. The punched pillows of Examples 1 to 4 were manufactured and the punchability was evaluated. The punching holes formed in the pressing body have a diameter of 5 mm, an interval of 15 mm, and a number of 119. A punching blade having a length of 50 mm was planted on the lower surface of the lifting plate in accordance with the position of the punching hole of the pressing body. The evaluation of punchability is ◎ when the punching can be performed satisfactorily and there are no burrs in the through hole, ○ when the burrs etc. remain slightly in the through hole, and when many burrs remain in the through hole △, and the case where the foam was stuck to the punching blade and could not be punched was marked with ×. Further, as Example 5, a commercially available polyurethane foam having a high rebound resilience and a relatively high hardness (rebound resilience 41%, hardness 49 N, manufactured by Inoac Corporation, product number ER-20) is 80 ×. The foam for a perforated pillow cut into a 350 × 500 mm pillow shape was also perforated in the same manner as in Examples 1 to 4 to produce a perforated pillow, and the punchability at that time was evaluated. Table 1 shows the measurement results of the density, rebound resilience, hardness, and evaluation of punchability.

  Moreover, except for the point which does not perform the said compression process with respect to the foam for a perforated pillow of the said Examples 1-5, it punches and forms similarly to an Example, and the perforated | open_hole of Comparative Examples 1-5 A pillow was manufactured. Furthermore, with respect to the foam for a perforated pillow made of a polyurethane foam having a low rebound resilience and a high hardness (rebound resilience 16%, hardness 175N, manufactured by Inoac Corporation, product number EGR-2), The holed pillow of Comparative Example 6 was manufactured by punching and forming holes without performing the compression step as in Comparative Examples 1-5. In addition, a polyurethane foam having a high rebound resilience and hardness (47% rebound resilience, hardness 92N, manufactured by Inoac Corporation, product number ERG-S) is used as a foam for a perforated pillow for general mattresses. On the other hand, the perforated pillow of the comparative example 7 was manufactured by punching and forming the hole without performing the compression step as in the comparative examples 1 to 5. Table 2 shows the punchability when manufacturing the perforated pillows of Comparative Examples 1 to 7.

  As is apparent from Table 1, in Examples 1 to 5, good through holes could be formed by punching. In addition, the punched portion can be pushed out of the foam during the punching and extruding step, and it is not necessary to remove the extruded portion from the foam in a subsequent step.

  On the other hand, in Comparative Examples 1 to 3 and 5 in which holes were punched and formed on the same foam as in Examples 1 to 3 and 5 without being compressed, the foam was clinging to the punching blade, and good punching I could not. Moreover, since the comparative example 4 had comparatively high hardness, there was little clinging of the foam with respect to a punching blade compared with comparative examples 1-3, but the burr | flash residue was confirmed by the through-hole. On the other hand, in Comparative Example 6 consisting of a foam having high hardness even with low resilience, and Comparative Example 7 consisting of a foam having high resilience modulus and hardness, that is, a foam used for a general mattress, compression A relatively good through hole could be formed even without a process. From this, a foam having low rebound and low hardness, specifically, a rebound resilience of 41% or less and a hardness of 90 N or less, particularly a rebound resilience of 30% or less (and more With respect to the foam having a rebound resilience of 20% or less and a hardness of 80 N or less (more preferably 10 to 70 N), by performing the compression step and the punching extrusion step, it is possible to punch holes well, A stamped piece can be extruded from the foam.

  In addition, market demand characteristics (functional requirements) required for a pillow pillow made of foam are low resilience and moderately low hardness. Such characteristics make the processing extremely difficult when performing secondary processing such as drilling or cutting in the foam. However, according to the present invention, even a pillow material having a low resilience and a low hardness can be punched extremely well, and the punched piece does not need to be removed in a subsequent process.

It is a schematic sectional drawing which shows the state which has arrange | positioned the foam to the press body in one Embodiment of this invention. It is a schematic sectional drawing which shows the compression state of a foam in the same embodiment. It is a schematic sectional drawing which shows the time of punching in the same embodiment. It is a schematic sectional drawing which shows the state which extracted the punching blade from the foam in the same embodiment. It is a schematic sectional drawing which shows a compression release state in the same embodiment. It is a perspective view of the perforated pillow obtained by the manufacturing method of the embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Perforated pillow 11 Foam 12 Through-hole 13 Punched part 21, 31 Press body 22, 32 Punching hole 51 Punching blade

Claims (5)

When manufacturing perforated pillows with through holes formed in foam,
A compression step in which a foam is disposed between two pressing bodies in which punching holes are formed and compressed with the two pressing bodies;
The punching blade is press-fitted from the punching hole of one pressing body toward the punching hole of the other pressing body, the foam between the two pressing bodies is punched by the punching blade, and the punched portion is A punching and extruding step of punching out the foam from the punching hole of the pressing body with the punching blade to the outside of the foam; and
A compression release step of releasing the compression of the foam by expanding the space between the two pressing bodies;
A method for producing a perforated pillow, characterized in that a perforated pillow is formed by: When manufacturing perforated pillows with through holes formed in foam,
Polyol (A-1) having a functional group number of 1.5 to 4.5 and a hydroxyl value of 150 to 300 mgKOH / g, and a polyol (A-2) having a functional group number of 1.5 to 4.5 and a hydroxyl value of 30 to 100 mgKOH / g A polyol (A) having an average hydroxyl value of 90 to 250 mg KOH / g and a polyisocyanate (B) having a weight ratio of 50:50 to 80:20 and an isocyanate index of 60 to 90 in the presence of a blowing agent and a catalyst. After reacting to form a foam,
A compression step in which the foam is placed between two pressing bodies in which punching holes are formed and compressed with the two pressing bodies;
The punching blade is press-fitted from the punching hole of one pressing body toward the punching hole of the other pressing body, the foam between the two pressing bodies is punched by the punching blade, and the punched portion is A punching and extruding step of punching out the foam from the punching hole of the pressing body with the punching blade to the outside of the foam; and
A compression release step of releasing the compression of the foam by expanding the space between the two pressing bodies;
A method for producing a perforated pillow, characterized in that a perforated pillow is formed by:   The method for producing a perforated pillow according to claim 1 or 2, wherein the foam is a low-rebound foam having a rebound resilience of 30% or less.   The method for manufacturing a perforated pillow according to any one of claims 1 to 3, wherein the foam is a molded product.   The method for manufacturing a perforated pillow according to any one of claims 1 to 4, wherein a compression ratio of the foam by the two pressing bodies is 5 to 40%.

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